CA2443072A1 - Use of comb-branched copolymers in gypsum compositions comprising comb-branched copolymers - Google Patents

Use of comb-branched copolymers in gypsum compositions comprising comb-branched copolymers Download PDF

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Publication number
CA2443072A1
CA2443072A1 CA002443072A CA2443072A CA2443072A1 CA 2443072 A1 CA2443072 A1 CA 2443072A1 CA 002443072 A CA002443072 A CA 002443072A CA 2443072 A CA2443072 A CA 2443072A CA 2443072 A1 CA2443072 A1 CA 2443072A1
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CA
Canada
Prior art keywords
gypsum
gypsum composition
dispersant formulation
copolymer
composition
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Granted
Application number
CA002443072A
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French (fr)
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CA2443072C (en
Inventor
Steven A. Schwartz
Mohamad A. Dehyar
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Coatex SAS
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Publication of CA2443072A1 publication Critical patent/CA2443072A1/en
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Publication of CA2443072C publication Critical patent/CA2443072C/en
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
    • C04B24/24—Macromolecular compounds
    • C04B24/26—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B24/2641—Polyacrylates; Polymethacrylates
    • C04B24/2647—Polyacrylates; Polymethacrylates containing polyether side chains
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/0028—Aspects relating to the mixing step of the mortar preparation
    • C04B40/0039—Premixtures of ingredients
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2/00—Processes of polymerisation
    • C08F2/38—Polymerisation using regulators, e.g. chain terminating agents, e.g. telomerisation
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/10—Esters
    • C08F220/26—Esters containing oxygen in addition to the carboxy oxygen
    • C08F220/28—Esters containing oxygen in addition to the carboxy oxygen containing no aromatic rings in the alcohol moiety
    • C08F220/285—Esters containing oxygen in addition to the carboxy oxygen containing no aromatic rings in the alcohol moiety and containing a polyether chain in the alcohol moiety
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F290/00—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups
    • C08F290/02—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups on to polymers modified by introduction of unsaturated end groups
    • C08F290/06—Polymers provided for in subclass C08G
    • C08F290/062—Polyethers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/30—Water reducers, plasticisers, air-entrainers, flow improvers
    • C04B2103/32—Superplasticisers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/40—Surface-active agents, dispersants
    • C04B2103/408—Dispersants
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C04B2111/0062—Gypsum-paper board like materials
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/04—Acids; Metal salts or ammonium salts thereof
    • C08F220/06—Acrylic acid; Methacrylic acid; Metal salts or ammonium salts thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/10—Esters
    • C08F220/26—Esters containing oxygen in addition to the carboxy oxygen
    • C08F220/28—Esters containing oxygen in addition to the carboxy oxygen containing no aromatic rings in the alcohol moiety
    • C08F220/285—Esters containing oxygen in addition to the carboxy oxygen containing no aromatic rings in the alcohol moiety and containing a polyether chain in the alcohol moiety
    • C08F220/288—Esters containing oxygen in addition to the carboxy oxygen containing no aromatic rings in the alcohol moiety and containing a polyether chain in the alcohol moiety and containing polypropylene-co-ethylene oxide in the alcohol moiety

Abstract

A gypsum composition suitable for use in the manufacture of construction materials is provided. The gypsum composition includes gypsum, water, and a dispersant formulation comprising an acrylic/polyether comb-branched copolymer. A method of making a gypsum composition is also provided. The method includes mixing together, in any combination, gypsum, water, and a dispersant formulation comprising an acrylic/polyether comb-branched copolymer. A wallboard is provided including two sheets of board paper, and a gypsum core between the sheets of board paper.

Claims (22)

1. A gypsum composition suitable for use in the manufacture of construction materials, said gypsum composition comprising:
a) gypsum;
b) water; and c) a dispersant formulation comprising an acrylic/polyether comb-branched copolymer.
2. The gypsum composition of claim 1 wherein the dispersant formulation is present in an amount effective to decrease the consistency of the gypsum composition relative to the consistency of a similar gypsum composition not containing the effective amount of the dispersant formulation.
3. The gypsum composition of claim 1 wherein the dispersant formulation is present in the gypsum composition in an amount effective to result in the copolymer being present in the gypsum composition in an amount of 0.001 to 1.0 weight percent, based on the total weight of the gypsum composition.
4. The gypsum composition of claim 1 wherein the dispersant formulation further comprises at least one inorganic setting accelerant selected from the group consisting of alkali metal sulfates, alkali earth metal hydroxides, and combinations thereof.
5. The gypsum composition of claim 4 wherein the inorganic setting accelerant comprises sodium sulfate and calcium hydroxide.
6. The gypsum composition of claim 4 wherein the dispersant formulation is present in an amount effective to decrease the consistency and initial set time of the gypsum composition relative to the consistency and initial set time of a similar gypsum composition not containing the effective amount of the dispersant formulation.
7. The gypsum composition of claim 5 wherein the copolymer, sodium sulfate, and calcium hydroxide are present in the dispersant formulation composition in a weight percent, based on the total weight of the gypsum in the gypsum composition, in the following amounts:
copolymer ~between 0.001 and 1.0 wt. %;
sodium sulfate ~between 0.01 and 5 wt. %; and calcium hydroxide between 0.0001 and 0.05 wt.%.
8. The gypsum composition of claim 1 wherein the pH of the copolymer is between 7 and 12.
9. The gypsum composition of claim 7 wherein the pH of the copolymer is between 7 and 12.
10. The gypsum composition of claim 1 wherein the dispersant formulation also comprises an additive selected from the group consisting of naphthalene sulfonate and calcium-based lignosulfonate.
11. A method of malting a gypsum composition suitable for use in the manufacture of construction materials, said method comprising mixing together, in any combination,:
a) gypsum;
b) water; and c) a dispersant formulation comprising an acrylic/polyether comb-branched copolymer.
12. The method of claim 11 wherein the dispersant formulation is provided in an amount effective to decrease the consistency of the gypsum composition relative to the consistency of a similar gypsum composition not containing the effective amount of the dispersant formulation.
13. The method of claim 11 wherein the dispersant formulation is provided in the gypsum composition in an amount effective to result in the copolymer being present in the gypsum composition in an amount of 0.001 to 1.0 weight percent, based on the total weight of the gypsum composition.
14. The method of claim 11 wherein the dispersant formulation further comprises at least one inorganic setting accelerant selected from the group consisting of alkali metal sulfates, alkali earth metal hydroxides, and combinations thereof.
15. The method of claim 14 wherein the inorganic setting accelerant comprises sodium sulfate and calcium hydroxide.
16. The method of claim 14 wherein the dispersant formulation is provided in an amount effective to decrease the consistency and initial set time of the gypsum composition relative to the consistency and initial set time of a similar composition not containing the effective amount of the dispersant formulation.
17. The method of claim 15 wherein the copolymer, sodium sulfate, and calcium hydroxide are present in the dispersant formulation in a weight percent, based.
on the total weight of the gypsum in the gypsum composition, in the following amounts:
copolymer between 0.001 and 1.0 wt. %;
sodium sulfate between 0.01 and 5 wt. %; and calcium hydroxide between 0.0001 and 0.05 wt. %.
18. The method of claim 11 wherein the pH of the copolymer is between 7 and 12.
19. The method of claim 17 wherein the pH of the copolymer is between 7 and 12.
20. The method of claim 11 wherein the dispersant formulation also.
comprises an additive selected from the group consisting of naphthalene sulfonate and calcium-based lignosulfonate.
21. A wallboard comprising:
two sheets of board paper; and a gypsum core between the sheets of board paper, the gypsum core being the set product of the gypsum composition of claim 1.
22. A wallboard comprising:
two sheets of board paper; and a gypsum core between the sheets of board paper, the gypsum core being the set product of the gypsum composition made in accordance with the method of claim 11.
CA2443072A 2001-04-11 2002-03-07 Use of comb-branched copolymers in gypsum compositions comprising comb-branched copolymers Expired - Fee Related CA2443072C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US09/832,646 US6527850B2 (en) 2001-04-11 2001-04-11 Use of comb-branched copolymers in gypsum compositions
US09/832,646 2001-04-11
PCT/US2002/007141 WO2002083594A1 (en) 2001-04-11 2002-03-07 Use of comb-branched copolymers in gypsum compositions comprising comb-branched copolymers

Publications (2)

Publication Number Publication Date
CA2443072A1 true CA2443072A1 (en) 2002-10-24
CA2443072C CA2443072C (en) 2011-12-13

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CA2443072A Expired - Fee Related CA2443072C (en) 2001-04-11 2002-03-07 Use of comb-branched copolymers in gypsum compositions comprising comb-branched copolymers

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US (1) US6527850B2 (en)
EP (1) EP1377533B1 (en)
JP (1) JP2004525061A (en)
AT (1) ATE387413T1 (en)
AU (1) AU2002250269A1 (en)
BR (1) BR0208843A (en)
CA (1) CA2443072C (en)
DE (1) DE60225259T2 (en)
ES (1) ES2299562T3 (en)
MX (1) MX233466B (en)
WO (1) WO2002083594A1 (en)

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Publication number Publication date
ES2299562T3 (en) 2008-06-01
EP1377533A1 (en) 2004-01-07
DE60225259D1 (en) 2008-04-10
CA2443072C (en) 2011-12-13
US20030019401A1 (en) 2003-01-30
ATE387413T1 (en) 2008-03-15
WO2002083594A1 (en) 2002-10-24
US6527850B2 (en) 2003-03-04
AU2002250269A1 (en) 2002-10-28
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MXPA03009274A (en) 2004-03-10
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